Slide out drive assembly for enclosure

ABSTRACT

A drive assembly for a slide out in an expandable enclosure, the drive assembly comprising a beam attachable to the slide out, the beam having a first row of teeth and a second row of teeth thereon, the first row of teeth and the second row of teeth extending parallel to each other on opposite sides of the beam wherein the teeth in the first row of teeth are offset relative to the teeth in the second row of teeth and a drive gear having a first gear wheel engagable with the first row of teeth and a second gear wheel engagable with the second row of teeth, and an actuator coupled to the beam to selectively extend and retract the beam.

CONTINUING APPLICATION DATA

This application is a continuation of U.S. patent application Ser. No.13/294,822, filed Nov. 11, 2011, the disclosure of which is incorporatedherein by reference.

TECHNICAL FIELD

This invention relates generally to an enclosure having one or moreslide outs used to reconfigure the enclosure. More particularly, theinvention relates to an enclosure having at least one slide out that maybe extended to alter the configuration of the enclosure and/or providemore room within the enclosure. Most particularly, the invention relatesto a drive assembly having a rack and pinion drive used to extend orretract the slide out.

BACKGROUND OF THE INVENTION

Expandable enclosures are often used in connection with recreationalvehicles or trailers that have portions that extend and retract to allowthe enclosure to be transported in a compact configuration and extendedto a more spacious configuration when stationary. To that end, theserecreation vehicles and trailers are provided with slide outs includingslidable rooms and other structures that increase or reconfigure theusable space. Existing slidable rooms and other slide outs may be timeconsuming to install and their operating mechanisms may includecomponents that add a great deal of weight and complexity to theenclosure. Since most enclosures having slide outs are used inapplications where they need to be transported, it is desirable toreduce the weight of the enclosure as practically as possible. Likewise,reducing the complexity of the slide out drive assembly is desirable interms of the labor needed to install the drive assembly and operation ofthe drive assembly by the user.

SUMMARY OF THE INVENTION

In one embodiment, a drive assembly for an expandable enclosure includesa beam having a first row of teeth and a second row of teeth thereon,the first row of teeth and the second row of teeth extending parallel toeach other on opposite sides of the beam. The teeth in the first row ofteeth are offset relative to the teeth in the second row of teeth. Thedrive gear has a first gear wheel engagable with the first row of teethand the second gear wheel engagable with the second row of teeth.

In another embodiment, a rack used in connection a drive assembly for anexpandable enclosure includes a beam having a pair of laterallyextending flanges, each flange having a row of teeth stamped therein.

In another embodiment, an expandable enclosure includes an enclosurehaving a side, a slide out portion formed in the side and extendabletherefrom. The enclosure further includes a drive assembly including abeam having a first row of teeth and a second row of teeth extendingparallel to each other and laterally spaced from each other by a centralportion. The beam is configured to attach to the slide out portion. Thedrive assembly also includes a drive gear assembly having a first gearwheel and a second gear wheel respectively engagable with the first rowof teeth and the second row of teeth, and a support wheel locatedbetween the first gear wheel and the second gear wheel. The supportwheel is configured to contact the beam between the first row of teethand the second row of teeth.

A method of constructing a beam in a drive assembly for a slide out,providing a die that stamps plural members having an upright section anda laterally extending flange, the laterally extending flange having arow of teeth formed therein, wherein the row of teeth extends less thanthe full length of the member, wherein each member produced by the diehas a first end and a second end, aligning a first member with uprightportions of each member adjacent to each other, and joining the uprightsections of the first and second members to form the beam with the tworows of teeth located on the flanges extending laterally outward fromthe joined upright sections.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective exterior view of a portion of an enclosurehaving a slide out according to the present invention, showing the slideout in an extended position;

FIG. 2 is a side elevational view of drive assembly for a slide outaccording to the invention;

FIG. 3 is a top perspective view of a drive assembly according to theinvention;

FIG. 4 is an enlarged bottom elevational view of a front portion of adrive assembly according to the invention;

FIG. 5 is an enlarged bottom elevational view showing a rear portion ofa drive assembly according to the invention;

FIG. 6 is a top perspective view of a drive assembly according toanother embodiment of the invention having two drive assembliesconnected by a cross-member;

FIG. 7 is a top plan view of the drive assembly shown in FIG. 6 with thedrive assembly shown in an extended position in dashed lines;

FIG. 8 is a partially sectioned front elevational view of the driveassembly depicted in FIG. 4; and

FIG. 9 is a sectional view as might be seen along line 9-9 in FIG. 4showing details of a drive gear assembly according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

An “enclosure” as used herein may include any partially or completelyenclosed space. The enclosure may be stationary or mobile. Mobileenclosures may be self-powered or towable, and include but are notlimited to mobile homes, recreational vehicles, and trailers. The term“expandable enclosure” refers to an enclosure that has the ability toalter its configuration and in some cases create more interior space.For example, an expandable enclosure may include one or more portionsthat extend and retract to selectively reconfigure the space defined bythe enclosure. These portions are often referred to as “slide outs” or“slideable rooms.” A slide out may include a portion that is movedrelative to the enclosure to change the configuration of the enclosureincluding but not limited to increasing the space available within theenclosure. Slide outs may be of various size and shape as required by agiven enclosure. Also, slide outs may expand and retract in any knownmanner including, but not limited to pivoting and telescoping relativeto the main portion of the enclosure. The example shown in theaccompanying drawings, therefore, should not be considered limiting.

FIG. 1 shows a portion of an enclosure 10 with a slide out 20 in anextended position. During movement or transport of the enclosure, theslide out 20 may be fully retracted to configure the enclosure 10 in acompact configuration. The enclosure has a wall 13 defining an opening12 into which the slide out 20 fits. Positioned about the edges of theopening 12 is a frame 14. Frame 14 may include side jambs 15, a header17, and a footer 19. In the example shown, the jambs 15, header 17, andfloor 19 are linear and joined at right angles to define a rectangularopening 12. The slide out 20 may be extended or retracted within frame14 to alter the configuration of enclosure 10 as needed. Optionally, aseal, such as a polymer strip may be provided about the frame 14 toprovide a weather tight seal between the frame 14 and the slide out 20.Slide out 20 may be of any size or shape as required by a givenapplication and may form a compartment, dinette, wardrobe, library,bedroom, closet, kitchen, etc.

Enclosure 10 may be a self powered vehicle, such as a recreationalvehicle, or may be towable, such as a trailer. The enclosure 10 may beone that is designed for living or temporary accommodation or maybe awork vehicle such as a mobile classroom, library, or temporary officespace. Alternatively, the enclosure 10 may be a stationary structureincluding but not limited to modular housing.

As shown in FIG. 2, a drive assembly, generally indicated by the number50 may be mounted adjacent to the frame 14. In the example shown, driveassembly 50 is located on or below floor 19 of enclosure 10. Driveassembly 50 may include a beam 52 that attaches to slide out 20 or mayform part of the frame of the slide out 20. In the example shown, an endbracket, generally indicated by the number 30 that attaches to a crossbar 32 that attaches to the floor 22 of slide out 20. Bracket 30 mayhave any shape or cross member 32 may attach directly to beam 52. In theexample shown, bracket 30 includes a face plate 34 that attaches to beam52 and to cross member or slide out 20 at its top section. To providefurther support for slide out 20 in the extended position, bracket 30may include a support 36 that extends downward to contact a supportingsurface. In the example shown, a telescopic support extends downwardlyfrom the end plate and has an end that may be rotating to release andextend the support downwardly to contact the supporting surface.

Beam 52 is moveable between a retracted position and an extendedposition to selectively extend and retract a slide out 20. As best shownin FIG. 4, beam 52 includes a first row of teeth 54 and a second row ofteeth 56 that are formed on opposite sides of the beam 52. The first rowof teeth 54 and second row of teeth 56 extend parallel to each otherand, as shown, may be formed on respective flanges on either side of thebeam 52. Teeth 54,56 may be formed in any known manner. For example, therows of teeth 54,56 may be stamped into beam 52. The beam 52 may be amonolithic member or be formed by multiple pieces.

According to one embodiment of the invention, beam 52 is formed by apair of c-shaped members 60 having a vertical center section 66 andoutwardly extending bottom and top flanges 62,64. These c-shaped membersare joined at the center sections and form a central channel or groove68 where the sections are joined together. In the example shown, therows of teeth are stamped into the bottom flange 62 on each c-shapemember such that the rows of teeth 54,56 are located on either side ofthe groove 68.

A drive gear assembly, generally indicated by the number 70, isconfigured to engage the first and second rows of teeth 54,56. Drivegear assembly 70 may include a first gear wheel 71 and a second gearwheel 72 that engage respective rows of teeth. The drive gear assembly70 may further include a support wheel 75 that engages beam 52 betweenthe first and second rows of gear teeth 54,56 to allow free movement ofbeam 52 in the axial direction. Support wheel 75, first gear wheel 71,and a second gear wheel 72 may all be mounted on a common hub 74 (FIG.9). The support wheel 75 may optionally be mounted on suitable bearingssuch that it rotates independently of hub 74. In the example shown,support wheel 75 is fixed to hub 74 and rotates with first and secondgear wheels 54,56.

The first row of teeth and second row of teeth 54,56 may be symmetricalabout the center line of beam 52. Optionally, as shown, the first row ofgear teeth and second row of gear teeth 54,56 may have an offset 78 inthe axial direction. The offset 78 may be any amount. For example, theoffset 78 shown is one and a half teeth. This offset ensures that atleast one tooth on each wheel is engaged at all times to help spread theload of slide out 20. Likewise, the first gear wheel and second gearwheel 71,72 may be mounted in a corresponding rotationally offsetpositions to mate with the off set rows of gear teeth 54,56. In thisway, greater stability is provided by maintaining contact with more thanone gear tooth on either side of the beam 52 at all times.

According to another aspect of the invention, a method of forming beam52 includes stamping a c-shaped member having a first end and a secondend. Stamping a second c-shaped member having a first end and a secondend in the same die. Each c-shaped member has a row of teeth formed on abottom flange. The teeth formed on the flange to a tooth on a gearwheel. The spacing of the teeth on gear wheels 71,72 and on rows 54,56may be set such that the cogs on gear wheels 71,72 contact the teeth inrows 54,56 in alternating fashion. An offset between rows 54,56 may beprovided to time contact of the teeth in this alternating fashion.

As best shown in FIGS. 3 and 4, the teeth in one row begin before theteeth in the opposite row and the teeth are spaced by an offset 78.According to one aspect of the invention a method of forming the offsetteeth in a single die is provided. A single die is provided to mold orstamp one half of beam 52. The mold creates a first beam member 52Ahaving a row of teeth 54 that start a first distance from a first end(FIG. 4) of first beam member and terminate a second distance from thesecond end (FIG. 5) of the first beam member. The first and seconddistances are not equal and differ by the amount of the desired offset78 between the rows of teeth. That way, when a second beam member 50B isprovided by the die, the second beam member may be rotated and joined tothe first beam member to create the second row of teeth 56 with thedesired offset 78 between the first and second rows of teeth 54,56.

In the example shown, beam is constructed by a pair of c-shaped beammembers having rows of teeth 54,56 formed as described above. Inparticular, the first c-shaped member having a first row of teeth 54 isprovided, and then a second c-shaped member is placed adjacent such thatits second end is adjacent to the first end of the first c-shapedmember. In other words, one of the c-shaped members is flipped aroundand placed back to back with the other c-shaped member. Once in thisconfiguration, the c-shaped members may be fastened or welded togetherto form beam 52. The fact that the rows of teeth 54,56 each have a toothprofile that corresponds to every other tooth on a gear wheel, and theoffset 78 between the rows of teeth causes alternating engagement of theteeth 54,56 by corresponding gear wheels 71,72. In other words, as thefirst gear wheel 71 moves toward disengagement the tooth on second gearwheel 72 is beginning to engage the second row of teeth 56.

As best shown in FIGS. 4 and 9, a stub shaft 80 may extend axiallyoutward from hub 74 and is connected to hub 74 such that rotation ofstub shaft 80 causes the first and second gear wheels 71,72 to rotateand drive beam 52. The stub shaft 80 may be manually rotated with anappropriate tool or driven by a motor. As shown in FIG. 7, a motor 101may be coupled to stub shaft 80 a drive assembly 50. A motor 101 may beprovided for each drive assembly, when using more than one driveassembly, or, as shown, stub shaft 80 may also be used to link andsynchronize multiple drive assemblies 50. There, a tandem drive assemblyis shown having two drive assemblies 50 linked by a cross member 90 thatcouples stub shafts 80 extending from each hub 74. Cross member 90 maybe any suitable coupler including but not limited to a telescopingsquare cross-sectioned tube as shown. In the example shown, tube isextended to fit over a stub shaft 80 on each drive assembly 50 andpinned in place. In this example motor 101 drives both drive assemblies50 via cross member 90.

By coupling drive assemblies 50, a pair of beams 52 may be used toextend and retract slide out 20 through a common actuator 100. Actuator100 may be a motor 101 (FIG. 7) coupled to drive assembly 50 or anelectric, hydraulic, or pneumatic cylinder that is coupled to a portionof drive assembly 50 to cause the beam 52 to extend and retract. In theexample shown, in FIGS. 3 and 6, an electric cylinder 102 is used andhas a telescoping rod 104 that attaches to an actuator bracket 106 thatis coupled to beam 52 through end plate 34. In the embodiment shown inFIG. 6, the actuator 100 drives one beam 52, which in turn causes thegear wheels 71,72 to rotate on teeth 54,56. Rotation of gear wheels71,72 rotates hub 74 and stub shaft 80, which is coupled by cross member90 to the hub 74 of opposite beam 52. Rotation of opposite hub 74, inturn, rotates gear wheels 71,72 on that hub to drive second beam 52 atthe same time first beam 52 is driven by actuator 100. FIG. 6 depictsextension of the drive assemblies to move the slide out to an extendedposition as shown in FIG. 1. The extended position is shown in dashedlines with the reference numerals indicated with a prime (′marking). Inparticular, as shown, in the extended position, actuator 100 drivesbeams 52 outwardly along with the cross member 32 that attaches to theslide out 20 to the extended position 52 prime, 32 prime.

The drive assembly may be mounted beneath the body of the enclosure 10or within the sub frame of the enclosure 10. Other locations may be useddepending on the orientation of the drive assembly. In the exampleshown, a pair of substantially parallel support rails 150 are providedto house and support beams 52. As shown, each support rail 150 has achannel-like configuration with a closed top wall 152 and downwardlyextending side walls 154. The bottom section 155 is partially closed bya pair of lower flanges 156 that extend inwardly toward each other. Asbest shown in FIG. 4, lower flanges 156 may extend inward an extent tosupport the edges 55 of beam 52. As shown in FIG. 3, lower flanges 156may not extend the entire length of support rail 150 providing clearance158 for gear wheels 71, 72 at the mouth of rail 150. Support rails 150may be attached to the frame of the enclosure 10 at either end. In theexample shown, a hanger 160 is provided at the outer end 162 of eachrail 150. The hangers 160 may be any structural member including a pairof L-shaped angle brackets 164 as shown. In the example shown, a firstleg 166 of hanger 160 extends parallel to the support rail 150 and isbolted to the sidewall 154 of the support rail 150 (FIG. 8). The secondleg 168, which is generally at a ninety degree angle to the first leg166 includes an opening 170 for mounting hanger 160 to the frame of theenclosure 10. A roller 175 may be supported on hanger 160 at the mouthof support rail 150. As best shown in FIG. 2, roller 175 may be mountedon a shaft that is supported in a slotted receiver 176 that allowsroller to travel vertically to avoid binding of beam 52 as it extendsoutward from support rail 150. Hanger 160 may also support a bearing 180that rotatably supports hub 74. As best shown in FIG. 9, stub shafts 80may form part of hub 74 with stub shafts 80 being rotatably supported inbearings 180 on either side of hub 74.

At the rear portion of support rail 150, a second hanger 182 is providedto support the rear end 159 of support rail 150 in the example shown, asingle hanger having a u-shaped cross-section is provided with a closedrear wall 184 and a pair of forwardly extending tabs 186. The rear wall184 is provided with openings 188 that receive fasteners 190 to attachedsecond hanger 182 to the frame of enclosure 10. In the example shown, aslotted opening 188 is provided on each tab 186 and extends verticallyto allow adjustment of the height of second end 159 of support rail 150.This provides an adjustment to facilitate attachment of beam 52 toenclosure or to allow beam 52 to be used in a flush floor slide out. Forexample, as best seen in FIG. 2, second end 159 may be raised to orientsupport rail 150 at a downward angle to position the floor of slide out20 flush with the floor of the enclosure 10. In particular, when theslide out 20 is fully extended, the downward angle of support rail 150and beam 52 allow the slide out 20 to drop down so that its floor isflush with the floor of the enclosure. In other applications, supportrail 150 may be oriented in a level position or at an upward angle.

Each support rail 150 defines a channel 151 that receives beam 52 andsupports beam 52 as it extends and retracts. A stop 192 may be providedat a rear portion of the channel 151 to adjust the length of the channel151 when using beams 52 of different lengths depending on the amount ofextension required for a given slide out 20. The stop 192 may also beused to align beam 52 within the channel. In the example shown, stop 192includes a yoke 194 having a pair of forwardly extending arms 196defining a gap 198 there between in which the center portion 66 of beam52 is received. Stop 192 may include one or more cross bars 200 thatsupport arms 196 and extend across the channel 151. As shown, cross bars200 may be supported on rollers 204 received within each sidewall 154 ofthe support rail.

As discussed previously, drive assembly 50 may include an electriccylinder used to extend and retract beam 52 from support rail 150.Cylinder 102 extends parallel to beam 52 and may be supported on supportrail 150, as shown. It will be appreciated that cylinder 102 may besupported on the frame of enclosure 10 or another structure as well. Inthe depicted example, a mounting plate 210 is attached to the supportrail, as by welds. The mounting plate 210 is provided with a number ofmounting holes 212 on either side to allow attachment of a cylinderbracket 214. As shown, holes 212 may be provided on both sides ofmounting plate 210 to allow attachment of cylinder 102 on either side ofsupport rail 150 depending on the location of the slide out 20. Theprovision of multiple mounting holes also provides flexibility forpositioning the cylinder 102.

Cylinder bracket 214 may have any configuration suited for a givencylinder 102. In the example shown, cylinder bracket 214 is generally anL-shaped member with a lower leg 216 attaching to the mounting plate 210and a pair of upstanding legs 218 that extend upward adjacent to supportrail 150. In the example shown, cylinder 102 is supported between theupstanding legs 218 and secured by a suitable fastener 220. A motor 222is coupled to electronic cylinder 102 and may be supported on an endplate 224 extending from one end of cylinder 102. Motor 222 may includean internal controller 225 that controls operation of motor 222. Inaddition, for remote operation, motor 222 may include an antenna 226.The user may operate motor 222, through a switch located withinenclosure 10 to selectively extend and retract slide out 20. Forexample, motor 222 is operated in one rotational direction to extend end104 of cylinder 102 to extend slide out 20, and rotated in the oppositedirection to retract end 104 and slide out 20.

What is claimed is:
 1. A drive assembly for a slide out in an expandableenclosure, the drive assembly comprising: a beam attachable to the slideout, the beam having a first row of teeth extending along on a firstside of the beam and a second row of teeth extending along an opposingsecond side of the beam, the first row of teeth and the second row ofteeth extending parallel to each other on the opposing first and secondsides of the beam, wherein the teeth in the first row of teeth areoffset relative to the teeth in the second row of teeth; and a drivegear having a first gear wheel engagable with the first row of teeth anda second gear wheel engagable with the second row of teeth; and anactuator coupled to the beam to selectively extend and retract the beam.2. The drive assembly of claim 1, wherein the drive gear includes asupport wheel located between the first and second gear wheels, thesupport wheel extending radially outward to contact the beam between thefirst row of gear teeth and the second row of gear teeth.
 3. The driveassembly of claim 2, wherein the first gear wheel, second gear wheel,and support wheel are mounted on a hub, the first gear wheel and secondgear wheel being rotatably fixed to the hub, while the support wheel isfreely rotatable thereon.
 4. The drive assembly of claim 1, wherein thefirst row of gear teeth and the second row of gear teeth are offset byone and one half teeth.
 5. The drive assembly of claim 1, wherein thebeam defines a groove between the first row of teeth and the second rowof teeth, the groove extending parallel to the first row of teeth andthe second row of teeth.
 6. The drive assembly of claim 1, wherein thebeam includes a pair of side flanges extending laterally outward from acentral portion, wherein the first row of teeth is stamped into one ofthe flanges and the second row of teeth is stamped into the other of theflanges.
 7. The drive assembly of claim 1, wherein the actuator includesa motor coupled to the first gear wheel and the second gear wheel. 8.The drive assembly of claim 1, wherein the actuator includes anelectronic cylinder having an extendable end coupled to the beam.
 9. Thedrive assembly of claim 1 further comprising a bracket mounted on an endof the beam, wherein the bracket attaches to the slide out.
 10. A rackused in connection With a slide out drive assembly, the rack comprising:a beam having a pair of laterally extending flanges, each flange havinga row of teeth stamped along a side thereof.
 11. The rack of claim 10,wherein the teeth in one row of teeth are offset relative to the otherrow of teeth.
 12. The rack of claim 11, wherein the teeth are offset bya distance of one and one half teeth.
 13. The rack of claim 11 furthercomprising a first gear wheel operatively engaging the first row ofteeth and a second gear wheel operatively engaging the second row ofteeth, wherein the teeth formed in the first and second rows are spaceda distance corresponding to two teeth on the respective first and secondgear wheel.
 14. The rack of claim 11 further comprising a centralportion formed by a pair of center flanges extending upward from inwardextremities of the laterally extending flanges. and the center flangesbeing joined together.
 15. The rack of claim 14, wherein a joint formedby the center flanges defines a groove between the laterally extendingflanges.
 16. An expandable enclosure comprising: an enclosure; a slideout extendable from the enclosure; a drive assembly including a beamhaving a first row of teeth extending along on a first side of the beamand a second row of teeth extending along an opposing second side of thebeam, the first row of teeth and the opposing second row of teethextending parallel to each other and laterally spaced from each other bya central portion of the beam, wherein the beam is configured to attachto the slide out; a drive gear including a first gear wheel and a secondgear wheel respectively engageable with the first row of teeth and thesecond row of teeth, and a support wheel located between the first gearwheel and the second gear wheel, the support wheel configured to contactthe beam between the first row of teeth and the second row of teeth; andan actuator operatively connected to the beam to extend or retract theslide out.
 17. The slide out assembly of claim 16, further comprising ahub, the first gear wheel and second gear wheel being rotatably fixed tothe hub.
 18. The slide out assembly of claim 17, wherein the hubincludes a first stub shaft extending axially outward therefrom.
 19. Theslide out assembly of claim 17 further comprising: a second driveassembly including a beam having a first row of teeth and a second rowof teeth extending parallel to each other and laterally spaced from eachother by a central portion, wherein the beam is configured to attach tothe slide out; a drive gear including a first gear wheel and a secondgear wheel respectively engageable with the first row of teeth and thesecond row of teeth, and a support wheel located between the first gearwheel and the second gear wheel, the support wheel configured to contactthe beam between the first row of teeth and the second row of teeth,wherein the first gear wheel and second gear wheel are rotatably fixedto a second hub having a second stub shaft extending axially outwardfrom the hub toward the first stub shaft; and a cross member connectingthe first stub shaft to the second stub shaft.